Woven Planar Footwear Upper

ABSTRACT

Aspects of the present invention relate to a shoe upper that is formed as a substantially planar article with varied functional zones integrated therein. The varied functional zones may be strategically positioned zones having varied degrees of stretch. Additionally, it is contemplated that the functional zones may provide dimensional variation (e.g., thickness) and/or permeability (e.g., breathability) characteristics. The substantially planar upper may then be formed into a three-dimensional upper having a volume that may be occupied by a wearer&#39;s foot.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation application of U.S. application Ser.No. 14/139,262, filed Dec. 23, 2013, and entitled “Woven Planar FootwearUpper,” which claims the benefit of U.S. Provisional Application No.61/745,269, filed Dec. 21, 2012, and entitled “Woven Footwear Upper.”The entirety of the aforementioned applications are incorporated hereinby reference.

BACKGROUND

The manufacturing of a shoe upper may involve sewing and adhering anumber of physically discrete pieces to result in a three-dimensionalvolume able to receive a wearer's foot. The manufacturing resourcesutilized to cut and secure the individual portions can be costly anddetrimental to the resulting quality of the shoe upper. Even though theincorporation of multiple physically discrete pieces may increase theburden on resource, the various discrete pieces may be utilized in theshoe upper to impart desired physical characteristics to the shoe upper.

SUMMARY

Aspects of the present invention relate to a shoe upper that is formedas a substantially planar article with varied functional zonesintegrally formed therein. The varied functional zones may bestrategically positioned zones having varied degrees of stretch.Additionally, it is contemplated that the functional zones may providedimensional variation (e.g., thickness) and/or permeability (e.g.,breathability) characteristics. The substantially planar upper may thenbe formed into a three-dimensional upper having a volume that may beoccupied by a wearer's foot. The upper having integrally formedfunctional zones may be formed in a single weaving operation thatintegrates the various functional zones in a common manufacturingprocess without utilizing post-processing coupling techniques tointegrate the functional zones.

This Summary is provided to introduce a selection of concepts in asimplified form that are further described below in the DetailedDescription. This Summary is not intended to identify key features oressential features of the claimed subject matter, nor is it intended tobe used as an aid in determining the scope of the claimed subjectmatter.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

Illustrative embodiments of the present invention are described indetail below with reference to the attached drawing figures, which areincorporated by reference herein and wherein:

FIG. 1 depicts a shoe comprised of a multi-zoned substantially-planarunitary upper in an as-worn position, in accordance with aspects of thepresent invention;

FIG. 2 depicts the upper in a substantially planar orientation, inaccordance with aspects of the present invention;

FIG. 3 depicts a lateral-side view of the upper formed in athree-dimensional state from the manufactured substantially planarstate, in accordance with aspects of the present invention;

FIG. 4 depicts a medial-side view of the upper formed in athree-dimensional state from the manufactured substantially planarstate, in accordance with aspects of the present invention;

FIG. 5 depicts a heel-end view of the upper formed in athree-dimensional state from the manufactured substantially planarstate, in accordance with aspects of the present invention;

FIG. 6 depicts toe-end view of the upper formed in a three-dimensionalstate from the manufactured substantially planar state, in accordancewith aspects of the present invention;

FIG. 7 depicts a top-down view of the upper formed in athree-dimensional state from the manufactured substantially planarstate, in accordance with aspects of the present invention;

FIG. 8 depicts a bottom-up view of the upper formed in athree-dimensional state from the manufactured substantially planarstate, in accordance with aspects of the present invention;

FIG. 9 depicts an exemplary portion of an upper having integrally wovenlockout strands, in accordance with aspects of the present invention;

FIG. 10 depicts an exemplary woven portion comprised of warps and weftswith non-orthogonally oriented lockout strands, in accordance withaspects of the present invention;

FIG. 11 depicts another exemplary woven portion comprised of warps andwefts with non-orthogonally oriented lockout strands, in accordance withaspects of the present invention;

FIG. 12 depicts a portion of an exemplary shoe having a lockoutassembly, in accordance with aspects of the present invention;

FIG. 13 depicts a cut-away, multi-layer, woven portion of an upper, inaccordance with aspects of the present invention;

FIG. 14 depicts an additional aspect of a substantially planar wovenshoe upper in both a front and a related back perspective, in accordancewith aspects of the present invention;

FIG. 15 depicts a spectrum of weaving techniques to achieve a variedmodulus of elasticity, in accordance with aspects of the presentinvention;

FIG. 16 depicts and exemplary heel region having a dimensional zone anda heel counter zone within a woven upper portion, in accordance withexemplary aspects of the present invention;

FIG. 17 depicts a cut profile of an ankle collar region, in accordancewith aspects of the present invention;

FIG. 18 depicts a multi-region woven portion, in accordance with aspectsof the present invention;

FIG. 19 depicts an exemplary woven article that utilizes a jacquardmechanism in combination with a leno weaving technique, in accordancewith aspects of the present invention;

FIG. 20 depicts an exemplary woven article having leno twisted weftsrunning in the vertical direction and pulled warps running in thehorizontal direction, in accordance with aspects of the presentinvention; and

FIG. 21 depicts an exemplary woven article having a monofilament warprunning in the horizontal direction and wefts running in the verticaldirection, in accordance with aspects of the present invention.

DETAILED DESCRIPTION

The subject matter of embodiments of the present invention is describedwith specificity herein to meet statutory requirements. However, thedescription itself is not intended to limit the scope of this patent.Rather, the inventors have contemplated that the claimed subject mattermight also be embodied in other ways, to include different elements orcombinations of elements similar to the ones described in this document,in conjunction with other present or future technologies.

Aspects of the present invention relate to a shoe upper that is formedas a flat article with varied functional zones integrated therein. Forexample, it is contemplated that a substantially planar shoe upper isproduced on a loom with strategically positioned zones having varieddegrees of stretch. Additionally, it is contemplated that the functionalzones may provide dimensional variation (e.g., thickness) and/orpermeability (e.g., breathability) characteristics. The substantiallyplanar upper may then be formed into a three-dimensional upper having avolume that may be occupied by a wearer's foot. The upper havingintegrally formed functional zone may be formed in a single weavingoperation that integrates the various functional zones in a commonmanufacturing process without utilizing post-processing couplingtechniques to integrate the functional zones.

FIG. 1 depicts a shoe 100 comprised of a multi-zonedsubstantially-planar unitary upper 202 in an as-worn position, inaccordance with aspects of the present invention. The construction ofthe shoe 100 of the present invention has the basic construction of anathletic-type shoe. However, it should be understood that the novelconcept of the invention could be employed on other types of footwear.Therefore, while the term “shoe” will be used herein, any type offootwear is contemplated for any purpose such that the term “shoe”should be interpreted herein as “footwear.” Because much of theconstruction of the shoe 100 is the same as that of a conventionalathletic shoe, the conventional features of the constructions will bedescribed only generally herein. Additionally, relative locationterminology will be utilized herein. For example, the term “proximate”is intended to mean on, about, near, by, next to, at, and the like.Therefore, when a feature is proximate another feature, it is close inproximity but not necessarily exactly at the describe location, in someaspects.

The shoe 100 has a shoe sole 102 that is constructed of resilientmaterials that are typically employed in the construction of soles ofathletic shoes. The sole 102 can be constructed with an outsole, amidsole, and an insert, as is conventional. The shoe sole 102 has abottom surface that functions as the traction surface of the shoe, andan opposite top. The size of the shoe 100 has a length that extends froma rear sole heel end 106 to a front toe end 104 of the sole 102. Thesole 102 has a width that extends between a medial side 110 and alateral side 108 of the sole 102.

The shoe 100 also is constructed with an upper 202. The upper 202 issecured to the sole 102 and extends upwardly from the shoe sole, such asthe sole top surface. The upper 202 is constructed of a flexiblematerial, such as a woven or knit material. The woven or knit materialmay be formed with a combination of materials. For example, syntheticmaterials, such as nylon, polyester, acrylic, carbon fibers, aramids,and other synthetic materials may be utilized in the forming of at leasta portion of the upper 202. Similarly, it is contemplated that naturalmaterials, such as cotton, wool, bamboo, soy-based, corn-based, andother natural materials may be utilized in the forming of at least aportion of the upper 202. Further, it is contemplated thatmulti-component materials may be utilized in the construction of aportion of the upper 202. As will be discussed hereinafter, it iscontemplated that combinations of materials may be utilized in variousregions of the upper 202 to form functional regions/zones in asubstantially planar upper being formed through weaving or knittingtechniques. As also will be discussed, varied manufacturing techniquesmay be implemented in specific zones of the upper 202 to achievestrategic variations in functional qualities at particular locations ofthe upper 202.

The upper 202 is constructed with a heel portion 206 that extends aroundthe sole 102 at the sole heel end 106. The upper heel portion 206extends upwardly from the shoe sole 102 to an ankle edge 261 defining,in part, an ankle opening 216. The ankle opening 216 provides access tothe shoe interior.

From the heel portion 206, the upper 202 has a medial side portion 210and a lateral side portion 208 that extend along the respective solemedial side 110 and the sole lateral side 108. The upper medial sideportion 210 extends upwardly from the sole medial side 110 to an uppermedial side edge 212. The upper lateral side portion 208 extendsupwardly from the sole lateral side 108 to an upper lateral side edge214. As illustrated in the figures, the upper medial side edge 212 andthe upper lateral side edge 214 extend rearwardly from opposite sides ofa toe box 204 forming, in combination, an upper edge 263, as seen inFIG. 2 hereinafter. As best seen in FIG. 1, the length of the uppermedial side edge 212 and the upper lateral side edge 214 define aforefoot opening 217 in the upper 202 that opens to the shoe interior103.

The upper 202 is also constructed with the toe box 204 that extendsaround and across the sole top surface at the sole toe end 104. The toebox 204 is connected between the upper medial side portion 210 and theupper lateral side portion 208 and encloses a portion of the shoeinterior 103 adjacent the sole toe end 104. The upper medial side edge212 and the upper lateral side edge 214 extend rearwardly from the toebox 204.

A plurality of lacing mechanisms 230 are provided on the upper medialside portion 210 and on the upper lateral side portion 208. The lacingmechanisms may be an aperture through which a string or lace is intendedto pass. Additional lacing mechanisms are also contemplated such ashooks, loops, integrated fibers/strings, and the like. For example, thelacing mechanism 230 may be a lacing opening that is typically occupiedby a portion of a fastener, such as lacing that close the shoe upperover the forefoot opening 217 of the shoe. However, in an exemplaryembodiment, the lacing mechanisms 230 are an eyelet or grommet styleaperture. The lacing mechanisms 230 are arranged in lines along theupper medial side portion 210 and the upper lateral side portion 208, asis conventional. As illustrated in the figures, the lacing mechanisms230, in an exemplary embodiment, extend substantially the entire lengthof the upper medial side edge 212 and the upper lateral side edge 214.

The shoe upper 202 includes a vamp 218 or a throat positioned rearwardlyof the toe box 204, and a tongue 220 that extends rearwardly from thevamp 218 through the forefoot opening 217. The tongue 220 extends alongthe lengths of the upper medial side portion 210 and the upper lateralside portion 208 to a distal end of the tongue near an ankle opening216. The length and width of the tongue position the tongue side edgesbeneath the upper medial side portion 210 and the upper lateral sideportion 208, and extend the tongue over the forefoot opening 217 of theshoe.

FIG. 2 illustrates the upper 202 in a substantially planar orientation,in accordance with aspects of the present invention. The term“substantially planar” means the upper is not formed into afoot-receiving form having an interior volume into which a foot may beinserted. “Substantially planar” does not imply a lack in thickness ordepth variation. To the contrary, a substantially planar upper 202 iscontemplated to have a heel dimensional region 274 (to be discussedhereinafter in greater detail) that intentionally forms a variedthickness region from other portions of the upper 202. A typical knit orwoven article as it comes off of a manufacturing machine (e.g., loom,knitting machine) may be in a sheet-like form, with the exception ofthree-dimensional knitting and weaving techniques. While these articlesare in a sheet-like state, they may have variations to thickness basedon differences in material utilized and/or techniques implemented.Therefore, a substantially planar article may include a sheet-likearticle having dimensional thickness variations, in an exemplary aspect.

As depicted in FIG. 2, the upper 202 is substantially planar andcomprised of a plurality of functionally varied regions. It iscontemplated that the upper 202 is formed, as depicted in FIG. 2, as anintegrally manufactured article. Stated differently, the upper 202 isformed in a unitary fashion from a common machine that utilizes varyingtechniques to impart the functional regions and dimensionalcharacteristics. This is in contrast to a typical shoe construction thatrequires a plurality of subsequent manufacturing processes to couple oneor more components to an underlying substrate to achieve variedfunctional zones. For example, a cut and sew (or bond) approach may beutilized in a typical upper construction where multiple discrete cutpieces are mechanically connected with sewing and/or adhesives in aseries of discrete events. Advantages of a unitarily formedsubstantially planar upper over traditional shoe manufacturing mayinclude reduced labor, reduced time, and greater quality control, in anexemplary aspect.

While the terms “medial” and “lateral” will be used herein for purposesof convenience, it is intended and understood that each term could besubstituted for the other term. Or, in the alternative, it is understoodthat generic terms, such as “first” and “second” could be substitutedfor either medial or lateral. This substitution is, in part, to allowfor a right shoe construction and a left shoe construction. Similarly,it is contemplated that some portions of the upper 202 may alternativelybe coupled (either integrally or mechanically) to an opposite side(e.g., the heel portion 206 may be integrally coupled with the medialside portion 210 as opposed to the illustrated lateral side portion 208,in an exemplary aspect).

Starting at the bottom leftmost portion of FIG. 2, the upper 202 iscomprised of a lateral heel edge 240. The lateral heel edge 240 isformed to be mechanically coupled with a medial heel edge 241 to form athree-dimensional upper. The lateral heel edge 240 is a portion of theupper 202 perimeter. The perimeter may be constructed having differentcharacteristics than other portions/regions of the upper 202. Forexample, it is contemplated that the perimeter, which is referenced as aperimeter region 260, may be formed as a multi-layer density weaveregion. The perimeter region 260 may have a relatively low modulus ofelasticity compared to other regions of the upper 202. Additionally, theperimeter region 260 may have multiple layers for reinforcement againstripping, tearing, unraveling, and other potentially destructivecharacteristics. In an exemplary aspect, the perimeter region 260 may beformed with a high density weaving technique that may incorporate variedmaterials (e.g., low stretch synthetic fibers). Additionally, it iscontemplated that the perimeter may be formed with a multi-layer weavingtechnique. Because the perimeter region 260 may be a region in whichmechanical fastening (e.g., sewing, bonding, tacking, and the like) maybe implemented to transform a substantially planar upper to a threedimensional upper, the enhanced resistance to deformation may beimplemented.

The lateral heel edge 240 extends downwardly from the top of theperimeter region 260, which is referred to as an ankle edge 261. Thelateral heel edge 240 extends down to a medial lower heel edge 255,which is also part of the perimeter region 260, in an exemplary aspect.The medial lower heel edge 255 continues around the heel portion 206 asit becomes a lateral lower heel edge 257. The combination of the mediallower heel edge 255 and the lateral lower heel edge 257 form a loweredge of the heel portion 206.

Continuing on from the lateral lower heel edge 257, the perimeterextends to a lateral heel flap edge 256. The lateral heel flap edge 256merges into a lateral flap edge 242 in the toewardly direction. Thelateral flap edge 242 forms into the lateral toe flap edge 244. Incombination the lateral heel flap edge 256, the lateral flap edge 242,and the lateral toe flap edge 244, in part, define a lateral sole flap252. The lateral sole flap 252, in an exemplary aspect, may be coupledwith an opposite medial sole flap 250 along the lateral flap edge 242 toform a bottom portion of the interior 103 of the shoe 100. Stateddifferently, the lateral sole flap 252 and the medial sole flap 250 maybe mechanically coupled to form, in part, a bottom surface of a threedimensional volume, as will be illustrated in FIG. 8 hereinafter.

Similarly, it is contemplated that the lateral heel flap edge 256 may becoupled with the lateral lower heel edge 257 to also form, in part, athree-dimensional volume, the interior 103. Further, it is contemplatedthat the lateral toe flap edge 244 and a lateral toe edge 245 may becoupled to also form, in part, a three-dimensional volume, the interior103.

Alignment of a first edge with a second edge may be accomplished, in anexemplary aspect utilizing one or more registers. For example, FIG. 2depicts a plurality of triangular registers extending from the perimeterportion 260. In a post-processing step in which a first edge ismechanically coupled (e.g., sewn, sealed, bonded, adhered) with a secondedge to form a three-dimensional volume, a first register from the firstedge may be aligned with a second register from the second edge.

The lateral toe edge 245 extends toewardly from the lateral toe flapedge 244 intersection around the toe box 204 as part of the perimeterregion 260. The lateral toe edge 245 merges into a medial toe edge 248.Together, the medial toe edge 248 and the lateral toe edge 245 form atoe edge defining a perimeter of the toe box 204.

The medial toe edge 248 intersects a medial toe flap edge 246. Themedial toe flap edge 246 intersects with the medial flap edge 243, whichextends heelwardly to a medial heel flap edge 254. The medial flap edge243 was previously discussed as a coupling edge in connection with thelateral flap edge 242. The medial heel flap edge 254 merges into themedial heel edge 241, which was previously discussed as being formed incomplement to the lateral heel edge 240. Together the medial toe flapedge 246, the medial sole flap 250, and the medial heel flap edge 254define, at least in part, a perimeter of the medial sole flap 250. Themedial toe flap edge 246 and the medial toe edge 248 are contemplated asbeing coupled, in part, to form the three-dimensional volume of theupper 202. Similarly, it is contemplated that the medial heel flap edge254 and the medial lower heel edge 255 are contemplated as beingcoupled, in part, to form the three-dimensional volume of the upper 202.As previously discussed, the medial sole flap 250 and the lateral soleflap 252 may be coupled to form a lower portion (e.g., sole-likesurface) of the upper 202 when in a three-dimensional configuration, asillustrated in FIG. 8 hereinafter.

In an exemplary aspect, it is contemplated that the medial sole flap 250and the lateral sole flap 252 are mechanically coupled with the sole 102of FIG. 1. For example, it is contemplated that the upper 202 is coupledwith the sole 102, at least in part by way of the medial sole flap 250and the lateral sole flap 252. It is also contemplated that the medialsole flap 250 and the lateral sole flap 252 may be positioned between aninsole inserted into the interior 103 of the shoe 100 and the topsurface of the outsole 102. Further, yet, it is contemplated that medialsole flap 250 and the lateral sole flap 252 may be positioned between abottom surface of a midsole portion and a top surface of an outsoleportion of the sole 102. It is further contemplated that alternativeand/or additional mechanism for coupling the upper 202 to the sole 102may be implemented.

The medial heel edge 241 extends along the medial side portion 210 tothe forefoot opening 217 as defined by the previously discussed medialside edge 212 and the lateral side edge 214. The lateral side edge 214extends heelwardly to intersect with the ankle edge 261, which, aspreviously discussed, intersects the lateral heel edge 240.

Together, the perimeter edges discussed define a substantially planarupper 202 that may be manufactured in a sheet-like manner having variedmaterials (e.g., organic, synthetic), varied manufacturing technique(e.g., differing weaving techniques), varied physical properties (e.g.,modulus of elasticity, impact attenuation), and varied geometricproperties (e.g., shape, dimension, thickness). It is furthercontemplated that the upper 202 may be formed in a multiple-unitoperation that results in a number of similar or different uppers to beformed during a common manufacturing operation. The uppers, such asupper 220, may then be removed from the multi-unit collection bycutting, trimming, sheering, etching, burning, melting, and other knowntechniques.

The upper 202 is also comprised of functionally-varied regions.Functionally-varied regions are portions of the upper 202 that havevaried physical characteristics from other portions of the upper 202.The varied physical characteristics may include a different modulus ofelasticity. As used herein, a modulus of elasticity is a measure ofability to stretch in one or more directions. For example, the upper 202may be comprised of a “non-stretch” portion, a “standard stretch”portion, and a “stretch” portion. The terms are not intended to beliterally interpreted, but instead intended to provide a relativemeasure of elasticity. Therefore, a stretch portion has a greatermodulus of elasticity than a non-stretch portion. This does not implythat a non-stretch portion is without stretch; instead, it means thenon-stretch portion is more limited in stretch than a standard orstretch portion of the upper 202.

The upper 202 may have strategically placed functional regions, such asstretch regions. For example, the upper 202 is illustrated in thisexemplary aspect as having a medial flap stretch region 270. The medialflap stretch region 270 is located on the medial side of the upper 202at the convergence of the medial sole flap 250 and the medial sideportion 210 approximate an arch location of a foot when received in theinterior 103. A corresponding lateral flap stretch region 272 is locatedon the lateral side of the upper 202 at the convergences of the lateralsole flap 252 and the lateral side portion 208. It is contemplated thatthe medial flap stretch region 270 and the lateral flap stretch region272 are functional to adapt the shape of the upper 202 as it is formedinto a three dimensional form having a sole, such as the sole 102. Theability to stretch in the strategic position and geometry provided, inan exemplary aspect, increases the ease of manufacturing a threedimensional object from a substantially planar form.

Another functional region contemplated is a toe stretch region 266. Thetoe stretch region 266 is integrated into a portion of the toe box 204of the upper 202. The toe stretch region 266 is functional to provide amore comfortable toe box 204 for a wearer. The toe stretch region 266may also improve the manufacturability of the shoe from thesubstantially planar form to a three dimensional form by providingadjustability and the ability to compensate when manipulated from aplanar to multi-dimensional state. It is also contemplated that a moredurable material may be integrated into the toe stretch region 266 toprotect the toe box 204 from damage.

The heel portion 206 is comprised of a heel stretch region 268. The heelstretch region 268 is functional to increase manufacturability andwearability of the resulting shoe. For example, the heel stretch region268 may allow for a more form-fitting upper 202 to a wearer's insertedheel region.

The forefoot region of the upper 202 is comprised of a combination of aforefoot non-stretch region 262 and a forefoot stretch region 264. Incombination, the two functional regions provide increased stability,wearability, and utility to the shoe. For example, the forefootnon-stretch region 262 is effective to transfer a lacing load applied byone or more lacing mechanisms. The load may be effectively transferredthrough the upper 202 downwardly towards a sole or merely around auser's inserted foot. The reduction of stretch in the forefootnon-stretch region 262 relative to surrounding areas allows for auniform distribution of load and tension to the upper 202 and aconnected sole. However, while the forefoot non-stretch region 262 maybe effective to distribute lacing mechanism forces, it may also reducethe wearability of the upper 202 by limiting stretch in the toe to heeldirection for a user during movements. Therefore, it is contemplatedthat the forefoot stretch region 264 is placed between portions of theforefoot non-stretch region 262, as illustrated. The forefoot stretchregion 264 inserts a degree of flexibility into the upper 202 thatincreases the wearability and ability to form to a user's inserted foot.

Stated differently, the forefoot non-stretch region 262 is formed in awave-like pattern extending from a crest-like position at the upper edge263 downwardly towards a flap or side edge. Each crest of the wave-likeform corresponds to a lacing mechanism, such as a second eyelet 234.Between two crests, the forefoot stretch region 264 is located. Theforefoot stretch region 264 may allow for a toe-to-heel directionseparation between two consecutive crests. Further, as illustrated, itis contemplated that the forefoot non-stretch region 262 follows the toeend of the forefoot opening across to the opposite side of the forefootopening. This uninterrupted continuation, in an exemplary aspect,provides structural integrity proximate the forefoot opening and furtheraids in effectively transferring loads asserted by a lacing mechanism.Additionally, it is contemplated that the forefoot non-stretch region262 extends toewardly proximate the toe box 204 to also providestructural integrity and effective transferring of lacing mechanismloads within the upper 202.

Another functional region contemplated is the heel dimensional region274, which is located in the heel portion 206 proximate a portion of theankle edge 261. The heel dimensional region 274 is a region that has agreater thickness from an interior surface to an exterior surface,sometimes referred to as a collar. Such a change inthickness/dimensionality may be accomplished by varying the materialutilized in producing the region. The variation may also be accomplishedby varying the manufacturing technique utilized in that region (e.g.,change from a plain weave to a dual-layer weave, allowing for floatingyarns, insertion of filler yarns). Additionally, it is contemplated thata multi-layer weave may be implemented that creates a pocket into whicha filler material may be inserted (e.g., injectable foam, injectableyarns). In an exemplary aspect, the injection of a material preventsdisturbing the structural integrity of the article by cutting an openingto insert a filler or other material. By injecting the material, theintegrity of the woven member may be maintained. The heel dimensionalregion 274 increases the wearability for a user of the shoe by providinga dissipation of force exerted by the heel portion 206 on the Achillesregion of a wearer. Further, the heel dimensional region 274 may providea better fit for the wearer as it has a greater volume to conform to thecontours of an inserted wearer's ankle.

The creation of a functional region may be accomplished in a number ofmanners. One technique contemplates utilizing different weavingtechniques to achieve a variation in functionality. For example, anon-stretch region may be formed utilizing a twill-like weavingtechnique. A stretch region may be accomplished by utilizing a satinweaving technique. A breathability region may be accomplished byutilizing a leno weaving technique, a hatching weaving, a slit weaving,and/or a plain-loose weaving technique (see e.g., FIG. 15).Additionally, it is contemplated that multiple layers may beincorporated to achieve the functional regions (e.g., additional layersfor reinforcement functionality).

It is contemplated that a first functional region may be surrounded by asecond functional region, in an exemplary aspect (see. e.g., FIG. 18).For example, it is contemplated that the heel stretch region 268 issurrounded by a transitional zone in which the material transitions fromthe stretch functionality to the standard functionality, which may beaccomplished by altering a manufacturing technique employed at the heelstretch region 268. Similarly, it is contemplated that the toe stretchregion 266 may be surrounded, in part, by another transitional region.The utilization of a transitional region in both examples may also beused to provide a reinforcement region to enhance the structuralintegrity of the upper 202. Similarly, it is contemplated that the heeldimensional region 274 is also surrounded, at least in part, by atransitional region. The transition region may provide a reinforcementborder to prevent creep of the dimensional volume with wear and use, inan exemplary aspect.

Another exemplary region of the upper 202 includes a breathabilityregion 275 in the toe box 204 of the upper 202. The breathability region275 may be formed from an open weave or otherwise looser materialconfiguration to allow for the permeability of air into an interior (orthe escape of air to the exterior).

While specific combinations and locations of functional regions aredepicted and discussed herein, it is contemplated that any combinationof functional regions may be implemented in any location and at anysize/shape. Therefore, the examples provided are not limiting, butinstead exemplary in nature. Additional functional zones may beimplemented in different location and in different combinationsutilizing different materials and different manufacturing techniquesthan those explicitly recited herein.

The ankle edge 261 is also comprised of a first eyelet 232. When thelateral heel edge 240 is coupled with the medial heel edge 241, thefirst eyelet 232 and the second eyelet 234 serve as the consecutiveeyelets in the three-dimensional upper form, as will be illustrated inFIG. 4 hereinafter.

FIG. 2 also depicts a relative modulus of elasticity in both theapproximate toe-to-heel direction and in the approximatemedial-to-lateral direction. In an exemplary aspect, it is contemplatedthat there is a greater degree of elasticity in the latter directionthan in the former direction. For example, the toe stretch region 266would have a greater modulus of elasticity in the medial/lateraldirection compared to the toe/heel direction, in an exemplary aspect.However, based on the exemplary configuration of the upper 202, becausethe heel portion is oriented perpendicular to the general toe-to-heeldirection, the greater degree of elasticity is in the ankle edge261—to—the lateral lower heel edge 257/medial lower heel edge 255direction as opposed to the lateral heel edge 240—to—the lateral sideportion 208 direction. This directional difference in elasticity may beaccomplished, in an exemplary aspect, utilizing a weaving techniquewherein the warps or the wefts are of a greater degree of elasticitythan the other of the warps/wefts, for example. It is contemplated thatthe degree of relative elasticity may be opposite than that which isdepicted in FIG. 2. Further, it is contemplated that the relativeelasticity may be similar in two or more directions, in an exemplaryaspect.

FIG. 3 depicts a lateral side view 300 of the upper 202 formed in athree-dimensional state from the manufactured substantially planarstate, in accordance with aspects of the present invention. The lateralside 108, the heel end 106, and the toe end 104 of the sole aredepicted. Similarly, the lateral side portion 208, the toe box 204 andthe heel portion 206 are depicted having a variety of functional zones.For example, the heel stretch region 268, the heel dimensional region274, the forefoot non-stretch region 262, the forefoot stretch region264, and the toe stretch region 266 are depicted. Additionally depictedin FIG. 3, is the ankle opening 216.

FIG. 4 depicts a medial side view 400 of the upper 202 formed in athree-dimensional state from the manufactured substantially planarstate, in accordance with aspects of the present invention. The medialside 110, the heel end 106, and the toe end 104 of the sole aredepicted. Similarly, the medial side portion 210, the toe box 204 andthe heel portion 206 are depicted having a variety of functional zones.For example, the heel stretch region 268, the heel dimensional region274, the forefoot non-stretch region 262, the forefoot stretch region264, and the toe stretch region 266 are depicted.

FIG. 4 also depicts the mechanical coupling of the lateral heel edge 240with the medial heel edge 241 to form an upper seam 402. The upper seam402 may be formed using any type of joining technique. For example,sewing, adhesives, laminating, mechanical fasteners, and the like arecontemplated. For example, it is contemplated that a combination ofsewing and adhesives, such as a thermal activated adhesive may beutilized. Further yet, it is contemplated that the upper seam 402 may beat any location and at any orientation. Therefore, it is contemplatedthat the upper seam 402 may be formed along an Achilles region of theheel portion such that there is a medial heel portion and a lateral heelportion of the substantially planar upper that when joined, form a seemproximate the Achilles region of a wearer. The first eyelet 232 and thesecond eyelet 234 are also depicted on each side of the upper seam 402in this exemplary aspect.

FIG. 5 depicts a heel end perspective 500 of the upper 202 formed in athree-dimensional state from the manufactured substantially planarstate, in accordance with aspects of the present invention. The heel end106, the medial side 110, and the lateral side 108 of the sole aredepicted. The heel portion 206 is depicted along with functionalregions, such as the forefoot non-stretch region 262, the heeldimensional region 274, and the heel stretch region 268. Additionalindicated is the ankle edge 261.

FIG. 6 depicts a toe end perspective 600 of the upper 202 formed in athree-dimensional state from the manufactured substantially planarstate, in accordance with aspects of the present invention. The toe end104, the medial side 110, and the lateral side 108 of the sole aredepicted. Additionally, the functional regions of the toe stretch region266 and the forefoot non-stretch region 262 are depicted. The firsteyelet 232 and the second eyelet 234 on either side of the upper seam402 are also depicted.

FIG. 7 depicts a top perspective 700 of the upper 202 formed in athree-dimensional state from the manufactured substantially planarstate, in accordance with aspects of the present invention. The toe end104, the heel end 106, the medial side 110, and the lateral side 108 ofthe sole are depicted. Additionally, the functional regions of the toestretch region 266, the breathability region 275, the forefootnon-stretch region 262, the forefoot stretch region 264, the heelstretch region 268, and the heel dimensional region 274 are depicted.Also depicted is the upper seam 402 on the medial side of the upper 202.

FIG. 8 depicts a bottom perspective 800 of the upper 202 formed in athree-dimensional state from the manufactured substantially planarstate, in accordance with aspects of the present invention. The depictedperspective is without a sole attached allowing a view of the variousedges mechanically coupled to form the three-dimensional form of anupper. In particular, the lateral sole flap 252 and the medial sole flap250 are depicted such that the lateral flap edge 242 is couple with themedial flap edge 243 are coupled joining the two sole flaps. Similarly,the lateral heel flap edge 256 and the medial heel flap edge 254 areillustrated and while not explicitly depicted, coupled to the laterallower heel edge 257 and the medial lower heel edge 255 respectively.Further, the lateral toe flap edge 244 and the medial toe flap edge 246are illustrated and while not explicitly depicted, coupled to thelateral toe edge 245 and the medial toe edge 248 respectively.

As will be discussed hereinafter, it is contemplated that one or morelockout strands or lockout strand assemblies may leverage the mechanicaljoining of the lateral flap edge 242 and the medial flap edge 243 tosecure and anchor one or more portions of a lockout strand. For example,a lockout strand that extends from a forefoot opening (e.g., as part ofa securing/lacing mechanism) may be secured within the seam formedbetween the lateral flap edge 242 and the medial flap edge 243. Further,it is contemplated that one or more portions of a lockout strand mayextend through the seam between the lateral flap edge 242 and the medialflap edge 243 such that when the formed upper is secured to a bottomunit (e.g., sole assembly), the one or more portions of the lockoutstrand are also secured to the bottom unit and/or the upper. Forexample, if an adhesive or other bonding agent is applied to a surfaceportion of the upper for securing to a surface of a bottom unit, theadhesive or bonding agent may also interact with the portions of thelockout strand(s) to secure those elements as well. Therefore, it iscontemplated that the sewing and or adhering that may be used to formthe upper and/or secure the upper to the sole may further aid inanchoring or securing one or more portions of a lockout strand, inexemplary aspects.

While a slip last type of construction is depicted, it is contemplatedthat any type of lasting construction may be implemented in exemplaryaspects. For example it is contemplated that a strobel last (e.g., amaterial is coupled with the upper along a perimeter portion roughlymatching a midsole perimeter) may be utilized in aspects. Further, it iscontemplated that a hybrid last may be utilized that incorporates two ormore lasting techniques. An example of a hybrid lasting may includeutilizing a strobel last in a heel region and a slip last in ametatarsal region of the foot.

Integrated Lockout Strand

It is contemplated that the following features may be implemented in asubstantially planar shoe upper. Additionally it is contemplated thatthe following features may be implemented in a three-dimensionalarticle, such as a formed shoe upper. Therefore, the following is notlimited to substantially planar shoe upper implementations.

FIG. 9 depicts an exemplary portion of an upper 900 having integrallywoven lockout strands, in an exemplary aspect. Lockout strands are amaterial having a relatively low modulus of elasticity (e.g.,substantially no stretch under normal usage scenarios). Examples oflockout strands include, but are not limited to, synthetic materials,organic materials, and multi-component structures. Further, it iscontemplated that a lockout strand may be a cable, thread, yarn,filament, cord, or any other structure suitable for providing anintegrated and/or inserted flexible member for use as a lockout strand.Specific example of a lockout strand include a nylon, a polyester, ametallic, a carbon fiber, and/or another material cable having adiameter between 0.5 millimeters and 2.0 millimeters. However, smallerand larger diameters are contemplated herein.

It is contemplated that a lockout strand forms, at least in part, anon-stretch functional region in a woven upper. As previously discussed,a non-stretch region may be formed utilizing a variety of weavingtechniques and/or materials. In an exemplary aspect, the utilization ofa lockout strand reduces the modulus of elasticity of a region of awoven shoe upper in at least one direction (e.g., in a directionparallel with the lockout strand, in a direction in which the lockoutstrand resists tension).

In an exemplary aspect, the lockout strands are functional to transfer atension load from a lacing apparatus (e.g., shoe lace) from the forefootregion around the medial and lateral side of a user's foot towards thesole. The lockout strands provide a zone of minimal stretch that iseffective for securing a shoe to the user's foot. In an additionalexemplary aspect, the utilization of lockout strands are integratedand/or inserted into a woven upper to provide zonal control of a modulusof elasticity. Therefore, it is contemplated that a region of a shoeupper that is desired to have a first attribute (e.g., breathabilityfrom a plurality of woven apertures) that may introduce a greater degreeof stretch than desired to that region, the lockout strands may also beutilized to achieve the desired modulus of elasticity while stillachieving the first attribute (as will be seen in FIG. 12 hereinafter).

Returning to FIG. 9, the upper 900 is woven with wefts and warpsgenerally in the direction of a first direction 902 and a seconddirection 904. As will be discussed with respect to FIGS. 10 and 11hereinafter, the lockout strands may extend in the first direction 902,the second direction 904, and/or a direction non-orthogonal to the firstdirection 902 and the second direction 904. Similar to the lockoutstrands, it is contemplated that the warps/wefts may be oriented inexemplary aspects in either the first direction 902 or the seconddirection 904. In an exemplary aspect, the lockout strands are depictedin an orientation substantially parallel with the wefts.

The upper 900 is comprised of a first region 906 and a second region908, in this exemplary aspect. The first region 906 may be a firstfunctional region and the second region 908 may be a second, different,functional region in an exemplary aspect. For example, it iscontemplated that the first region 906 may be a ventilation regionallowing for a greater degree of air/moisture movement through the upper900 that the second region 908, which may be a reinforcement region, forexample. As depicted, a first group 910 of lockout strands and a secondgroup 912 of lockout strands extend in from the first region 906 intothe second region 908 in a direction substantially parallel to the firstdirection 902.

The first group 910 is comprised of a first lockout strand 914, a secondlockout strand 916, and a third lockout strand 918. While three lockoutstrands are depicted, it is contemplated that any number may be used inany orientation. The lockout strands 914 and 196 are offset as to whichelements in the second direction 904 they are interwoven. Thisoffsetting may be utilized to achieve a stronger integration of thelockout strands with a region of the woven upper 900.

In an exemplary aspect, the first group 910 may extend from a lacingmechanism proximate a forefoot opening (or any location) of the upper900. For example, it is contemplated that an eyelet is formed into theupper 900 through the creation of an aperture during the weavingprocess. The first group 910 may be interwoven with the upper 900proximate (and even potentially around) the aperture. Therefore, thefirst group 910 is effective to transfer a force applied to the lacingmechanism (e.g., eyelet) by a lacing structure downwardly towards a sole(e.g., a midsole portion). In tan exemplary aspect, the second region908 may be an integrally woven reinforcement zone that terminates,securely, within the second region 908 by way of the weaving techniqueimplemented in the second region 908, in this example.

FIG. 10 depicts an exemplary woven portion 1000 comprised of warps andwefts with non-orthogonally oriented lockout strands, in accordance withaspects of the present invention. An exemplary non-orthogonally orientedlockout strand 1006 is integrated with members in a substantially firstdirection 1002 while floating over members oriented in a seconddirection 1004. The members in the first direction 1002 are the warps,in an exemplary aspect.

The lockout strand 1006 has a first portion 1008 and a second portion1010 with an apex 1014. At the apex 1014, an exemplary angle 1012 isformed. It is understood that the angle 1012 may be any angle. In thedepicted aspect, the angle 1012 may be a right angle, which results in asubstantially 45 degree traverse of the first direction 1002 and thesecond direction 1004, in this example. However, it is contemplated thatany angle of traverse of any members is contemplated to achievenon-orthogonally oriented lockout strand integration.

The apex 1014 represent a point in which the lockout strand 1006 changesfrom a first primary direction to a second primary direction. While theapex 1014 is depicted as occurring on the underlying warp/weftsubstrate, it is also contemplated that the apex 1014 may be beyond thesubstrate (e.g., past an edge). The apex extending past an edge mayprovide a lacing mechanism portion, such as a loop through which alacing structure may be inserted.

FIG. 11 depicts an exemplary woven portion 1100 comprised of warps andwefts with non-orthogonally oriented lockout strands, in accordance withaspects of the present invention. An exemplary non-orthogonally orientedlockout strand 1106 is integrated with members in a substantially firstdirection 1102 while floating over members oriented in a seconddirection 1104. The members in the first direction 1102 are the wefts,in an exemplary aspect.

The lockout strand 1106 has a first portion 1108 and a second portion1110 with an apex 1114. At the apex 1114, an exemplary loop 1112 isformed. As with FIG. 10, it is contemplated that the lockout strand 1106may traverse at any angle relative of any members is to achievenon-orthogonally oriented lockout strand integration.

The loop 1112 may be utilized as part of a lacing mechanism, as previousdiscussed. Additionally, it is contemplated that the loop 1112 may becoupled with one or more portions of a shoe. For example, upon lastingan upper having the loop 112, the loop 112 may be sewn (or otherwisecoupled) with the last. For example, the loop 1112 may be integratedinto a strobel stitch or a slip last stitch to securely anchor thelockout strand to a portion of the resulting shoe, such as the midsole.While the apex 1114 is depicted as extending beyond a warp/weftsubstrate, it is contemplated that the apex 1114 may occur within thewarp/weft substrate at any location.

As depicted, it is contemplated that a lockout strand mat be interwovenwith the warps and/or wefts of an underlying substrate. For example,during the weaving process utilizing traditional warps and wefts, thelockout strand may be integrated during the movement of heddles, priorto packing the shed, and/or following the packing of the shed, but priorto removing the woven article from the loop. It is contemplated that ajacquard-type loom may be utilized to form the substrate and anattachment may be positioned proximate the shed of the substrate comingoff the loom that is responsible for interweaving the lockout strand.Additionally, it is contemplated that a traditionally weft may bereplaced or augmented with a lockout strand during the weaving processto achieve an interwoven lockout strand. Further, it is contemplatedthat a warp may be replaced or augmented with a lockout strand to alsoachieve an integrally formed interwoven lockout strand in the warpdirection.

Lockout Assembly

It is contemplated that the following features may be implemented in asubstantially planar shoe upper. Additionally it is contemplated thatthe following features may be implemented in a three-dimensionalarticle, such as a formed shoe upper. Therefore, the following is notlimited to substantially planar shoe upper implementations.

FIG. 12 depicts a portion of an exemplary shoe 1200, in accordance withaspects of the present invention. The shoe 1200 is comprised of an upper1202 that forms a cavity between an exterior layer 1206 and an interiorlayer 1207 utilizing a multi-layer weaving technique. The cavityprovides a volume of space in which a lockout strand may be inserted toserve as a functional member of the upper 1202.

For example, it is contemplated that a lockout strand 1214 may passthrough the cavity along the lateral side portion 1208. The lockoutstrand may then go through the exterior layer 1206 at an aperture 1212.The aperture, as previously discussed, may be formed with aperturereinforcement 1210, such as a non-stretch region integrally formed withthe exterior layer 1206. The lockout strand may form a loop 1216 that isserves as a lacing mechanism through which a lace 1218 (or any otherlacing structure) may pass.

Within the cavity between the exterior layer 1206 and the interior layer1207, the lockout strand may extend downwardly towards a sole of theshoe 1200. It is contemplated that the cavity may have a perimeter wherethe multiple layers are integrally formed as a single layer, such aswith a jacquard loom. At the cavity perimeter, the lockout strand 1214may be coupled with the upper, such as with a lasting stitch (e.g.,strobel stitch). Additionally, it is contemplated that the lockoutstrand may pass through another aperture to be coupled with one or moreother portions of the shoe 1200.

As depicted in FIG. 12, a plurality of the lockout strands pass throughthe internal cavity of the lateral side portion 1208. While each lockoutstrand is depicted as exiting the cavity through a unique aperture, itis contemplated that one or more lockout strands may share a commonaperture. Further, it is contemplate that a lockout strand may exit thecavity through a first aperture and may loop back to re-enter the cavityat a second aperture, in an exemplary aspect. Further, it iscontemplated that the lockout strand is incorporated into a lacingmechanism, such as an eyelet within the upper 1202 proximate a forefootopening.

Also depicted in FIG. 12 is a zonal reinforcement 1211. The zonalreinforcement 1211 is positioned along the forefoot opening and is alsointegrated into the aperture reinforcement 1210, in an exemplary aspect.The zonal reinforcement 1211 may be an integrally woven zone or anapplied zone (e.g., laminate). The zonal reinforcement 1211 may providea non-stretch or reinforcement function aiding in the securing of thefoot to a user's foot.

FIG. 13 depicts a cut-away, multi-layer, woven portion 1300 of an upper1302, in accordance with aspects of the present invention. As previouslydiscussed, it is contemplated that an internal cavity may be formedduring a common weaving process using a weaving technique, such as thatperformed by a jacquard loom. The multi-layer woven article can take asingle layer and diverge into two or more layers during the weavingprocess. Consequently, if a cavity is desired, an interior layer 1307and an exterior layer 1306 may be formed to define an internal cavity1308.

As previously discussed, the internal cavity formed in a woven shoeupper may provide a volume through which a lockout strand may beinserted. For example, a lockout strand 1310 is depicted as passingthrough the cavity 1308 and out of the cavity, through the exteriorlayer 1306, at an aperture 1316. In this depicted example, the lockoutstrand forms a loop 1312 after exiting the cavity 1308. As contemplatedherein, the loop 1312 may be utilized as a lacing mechanism.

In an exemplary aspect, it is contemplated that the cavity 1308 forms afunctional zone, such as a filled pocket. The cavity 1308 may be filledwith floating yarns, padding, fibers, injectable foam, foam, and otherfillers 1314 (e.g., spacer mesh—a knit or woven dimensional materialhaving a first surface and a second parallel surface spaced apart andmaintained by elements extending between said surfaces) and impactattenuators.

In an exemplary aspect, the fillers 1314 may be inserted to separate theinterior layer 1307 from the exterior layer 1306 to facilitate theinsertion or incorporation of the lockout strand 1310, in an exemplaryaspect. For example, it is contemplated that a spacer mesh material (orany filler material) may be inserted into a cavity formed between twolayers of a woven article. The spacer mesh, in this example, may provideseveral functional advantages.

First, it is contemplated that when weaving a multi-layer portion of awoven article, a number of threads (or fibers) forming each surface isreduced by the number of layers being formed. For example, in atwo-layer pocket as contemplated herein, the number of warps may be halfthat of a single layer construction. Therefore, it is contemplated thatthe spacer mesh material may provide structural support and/orstructural integrity to compensate for the reduced density of wovenfibers caused by the formation of multiple layers. Further, it iscontemplated that the lockout strands may be inserted into thepocket/cavity after formation of the substantially planar woven upper.

The insertion may be aided by the dimensional characteristics of aspacer mesh that ensures the interior layer 1307 and the exterior layer1306 are maintained separate to provide a convenient path for insertionof the lockout strand without unintentionally breaching either of thelayers. Further to this point, the spacer mesh material (or any filler)may allow for a dispersion of forces applied by the lockout strand asexperienced by a wearer's foot when in an as-worn configuration. Forexample, to limit the sensation of tension along the side of a foot, thefiller material may aid in dispersing the energy across a greaterportion of the wearer's foot, in an exemplary aspect.

In a further aspect, the use of spacer mesh or any filler material mayallow for the absence of specifically engineered channels through whichthe lockout strands may extend. For example, a more general pocket maybe formed that is not sized and positioned specifically for a lockoutstrand, but instead, the pocket may be formed for receiving the fillermaterial that may be used for multiple lockout strands that extend therethrough in varied and shoe-specific path. Stated differently, theimplementation of a filler or spacer mesh adds adaptability to themanufacturing process as specific channels or features do not need to beformed for individual lockout strands. Instead, a general pocket may beformed having greater tolerances that is adapted to receive thefiller/spacer mesh. The received spacer mesh/filler may not be formedhaving a specific channel through which the lockout strand extends, butinstead the lockout strand may pass through any portion of a volume ofthe filler/spacer mesh.

Manufacturing Techniques

It is contemplated that any type and combination of manufacturingtechniques may be implemented in exemplary aspects. For example, it iscontemplated that a substantially planar upper may be formed in a loomthat is functional to alter the materials and weaving techniquesutilized in one or more regions. Similarly, it is contemplated that aknitting machine may be implemented to form a substantially planarupper, as provided herein.

Traditionally, weaving utilizes two distinct directional sets ofyarns/threads/fibers/filaments that are interlaced orthogonally to oneanother to form the resulting cloth or fabric. For example, a firstdirectional set running in a first direction of the resulting fabric maybe referred to as a warp set, or “warps” for short. Interlaced at aright angle to the warps are a second directional set, referred to as aweft set, or “wefts” for short. Stated differently, longitudinalelements (e.g., threads, yarn, fibers, and filaments) of a woven articleare the warp and the lateral elements are the weft.

Depending on a number of factors, characteristics of the resultingfabric may be affected. Those characteristics may include, but are notlimited to, the fabric's size, shape, feel, look, texture, impactabsorption/attenuation/response, moisture repellency/wicking, thermalenergy insulation/dissipation, and the like. Factors that arecontemplated as affecting the characteristics include, but are notlimited to how the warp and weft are interwoven. Additionally, dependingon the size of the elements utilized in the warp and/or the weftrelative to other warp and/or weft affect the resulting fabriccharacteristics. The type of material from which individual (or sets) ofelements are formed (e.g., twisted fibers, synthetic filaments,multi-material filaments, and the like) also may affect thecharacteristics. Reactions and other in-line and post-processingactivities (e.g., introduction of stimulus to a reactive material orportion of material) may affect the resulting characteristics of thefabric. Other variables that are manipulated during the weaving processmay also affect the resulting characteristics (e.g., tension, loom type,loom characteristics, temperature, and the like). Other variables areconsidered. Exemplary techniques and mechanisms for manufacturing one ormore articles utilizing one or more techniques are also contemplated anddescribed in co-pending, commonly assigned, U.S. Provisional No.61,590,177, filed Jan. 24, 2012, entitled “Intermittent WeavingSplicer,” U.S. Provisional No. 61/590,179, filed Jan. 24, 2012, entitled“Weaving Finishing Device,” U.S. Provisional No. 61/590,183, filed Jan.24, 2012, entitled “Multi-Functional Weaving System,” and U.S.application Ser. No. 13/599,531, filed Aug. 30, 2012, entitled “WovenTextile Bag,” which claims priority to U.S. Publication No. 61/529,049,filed Aug. 30, 2011, entitled “Woven Textile Apparel And Accessories,”all of which are incorporated by reference in their entirety herein.

The formation of a woven product, such as a shoe upper, may occur on aloom-like device. In an exemplary aspect, the loom holds the warpthreads in place as weft threads are interlaced in a repeating ornon-repeating manner. It is also contemplated that other devices may beimplemented other than a traditional loom to form a woven article. Forexample, tablet weaving, back-strapping, and other techniques arecontemplated.

As will be discussed and described in more detail hereinafter, it ispossible to implement any number of weaving techniques. In a plain weave(see e.g., FIG. 15) the warp and weft are aligned so they form a simplecriss-cross pattern, which may be balanced so that there are the samenumber of ends per inch (i.e., warps) and picks per inch (i.e., wefts).Another example weaving pattern that is contemplated herein is a twillweave (see e.g., FIG. 15). In a twill weave, a pattern of diagonalparallel ribs (also referred to as a wale) may be visible. The ribs areformed by passing the weft over one or more warps and then under two ormore warps. The following row of wefts then are offset by one or morewarps from the previous row providing a stepping pattern. Additionally,a satin weave is contemplated (e.g., See FIG. 15). A satin weave mayhave four or more wefts floating over a single warp or vice versa. Thetype of woven process employed is not limited to plain, twill, or satin,but instead they are merely exemplary in nature and may form a buildingblock from which the ultimate weaving process is selected. As will bediscussed with respect to FIG. 15 hereinafter, it is contemplated that amodulus of elasticity (e.g., stretachability) may fall on a spectrumfrom stretchy to non-stretchy. In an exemplary aspect, that spectrum ofstretchy to non-stretchy may include the satin weave on a stretchier endfrom a twill weave on a less stretchy end. The plain weave may be placedon the spectrum of modulus of elasticity between a satin and a twillweave.

In addition to traditional weaving techniques, it is also contemplatedthat a dobby, jacquard, or other mechanism may be implemented formanipulating heddles or harness (es) controlling the position of one ormore warps to form the resulting woven article. Therefore, anycombination of weaving techniques may be implemented.

In the alternative of weaving, it is also contemplated that asubstantially planar upper may be formed utilizing a knitting technique.A knit article, such as a shoe upper, is an article formed, in anexemplary aspect, through a method of integrating consecutive rows ofloops (e.g., stitches) with a subsequent row of loops. A new loop in asubsequent row is pulled through an existing loop of a previous row, inan example. In knitting a yarn/fiber/thread/filament follows a courseforming the symmetric loops (i.e., bights) symmetrically above and belowthe mean path of the yarn. A variety of stitches (e.g., knit or purl,slip-stitch fair-isle, drop-stitch) may be implemented to providevarious functionality (e.g., elasticity), dimensional effects (e.g.,ribbing, welting, basket weaving) and aesthetic results. Any combinationof materials and stitching techniques may be implemented in one or moreaspects of the present invention.

A single spun yarn may be knitted as is, or it may be braided or pliedwith another yarn. In plying, two or more yarns are spun together. Whenspun together, a direction of spinning may be opposite from which theyarns were originally spun (if at all); for example, two Z-twist yarnsmay be plied with an S-twist. The opposing twist may relieve some of theyarns' tendency to curl up and produces a thicker, balanced yarn. Pliedyarns may themselves be plied together, producing cabled yarns ormulti-stranded yarns. Sometimes, the yarns being plied are fed atdifferent rates, so that one yarn loops around the other, as in bouclé.

Exemplary Aspects—Substantially Planar

The following exemplary aspects make reference to features previouslydiscussed with respect to FIG. 2 hereinabove. While specific featuresare identified from FIG. 2, they are not limiting but instead providedfor convenience. Stated differently, it is intended for the additionalaspects that are enabled herein, but that are not specificallyidentified below, are also contemplated within the scope of the presentinvention. Therefore, the exemplary part numbering provided hereinafteris not intended to limit the scope of the present invention. Forexample, FIG. 14 demonstrates a similar, but different, exemplarysubstantially planar upper, in accordance with aspects of the presentinvention.

An exemplary aspect is a woven substantially planar shoe upper that iscomprised of a woven first side portion (e.g., medial side portion 210,lateral side portion 208) extending from a first coupling edge (e.g.,medial heel edge 241, lateral heel edge 240) at a heel end towards a toeend and also extending from an upper edge (e.g., upper edge 263) towardsa first side edge (e.g., medial flap edge 243, lateral flap edge 242),the upper edge defining, in part, a forefoot opening (e.g., forefootopening 217) and an ankle opening (e.g., ankle opening 216) into aninterior (e.g., interior 103) of the shoe upper portion when the shoeupper portion is formed as a non-planar shoe upper.

The upper is also comprised of a woven second side portion (e.g., medialside portion 210, lateral side portion 208) extending from the heel endtowards the toe end and also extending from the upper edge towards asecond side edge (e.g., medial flap edge 243, lateral flap edge 242),the second side portion and the first side portion form, in part, amedial side and a lateral side of the shoe upper portion when the shoeupper portion is formed as a non-planar shoe upper.

The upper is further comprised of a woven toe region extending betweenthe first side portion at the toe end and the second side portion at thetoe end, the toe region also extending towards the upper edge forming atoe end of the forefoot opening. The upper is also comprised of a wovenheel region extending from an ankle edge (e.g., ankle edge 261) to aheel sole edge (e.g., medial lower heel edge 255, lateral lower heeledge 257) and also extending between the heel end of the second sideportion and a second coupling edge (e.g., lateral heel edge 240, medialheel edge 241). The first side portion is seamlessly (e.g., woven duringa common weaving operation, knit during a common knitting operation)coupled with the toe region. The toe region is also seamlessly coupledwith the second side portion. Further, the second side portion isseamlessly coupled with the heel region. The first side portion, thesecond side portion, the toe portion, and the heel portion aresubstantially planar. For example, it is contemplated that all portionsprovided in this exemplary upper were formed during a common weavingoperation that also may have incorporated various functional regions.

In an additional exemplary aspect, it is contemplated that a woven shoeupper is comprised of a woven heel portion having an ankle edge and anopposite heel sole edge. The heel portion is comprised of a dimensionalportion, a stretch portion, and a non-stretch portion, in this exemplaryaspect. The dimensional portion has a thickness greater than the stretchportion and the non-stretch portion. The dimensional portion, thestretch portion, and the non-stretch portion are integrally formed, suchas in a common weaving operation.

The upper is further comprised of a woven toe portion having a forefootedge and an opposite toe sole edge (e.g., medial toe edge 248, lateraltoe edge 245). The toe portion comprised of a stretch portion (e.g., toestretch region 266) and a non-stretch portion (e.g., a transitionalregion, perimeter region 260). The stretch portion and the non-stretchportion integrally formed, such as during a common manufacturingtechnique (e.g., a weaving operation).

The upper is also comprised of a woven medial side portion extendingbetween the heel portion and the toe portion on a medial side of theshoe upper, the medial side portion having a first upper edge (e.g.,medial side edge 212) and an opposite medial sole edge (e.g., medialflap edge 243, medial toe edge 248). The upper is comprised of a wovenlateral side portion extending between the heel portion and the toeportion on a lateral side of the shoe upper, the lateral side portionhaving a first upper edge and an opposite lateral sole edge (e.g.,lateral flap edge 242, lateral toe edge 245).

Another exemplary aspect of the present invention is a shoe constructioncomprised of a sole and an upper. The upper is comprised of a medialside portion and a lateral side portion. The medial side portion iscomprised of a) a first region extending from a forefoot opening towardsthe sole; b) a second region extending from the forefoot opening towardthe first region, the second region having a greater modulus ofelasticity than the first region; and c) a first aperture extendingthrough the medial side portion proximate the forefoot opening withinthe first region. The lateral side portion is comprised of a) a thirdregion extending from a forefoot opening towards the sole; b) a fourthregion extending from the forefoot opening toward the third region, thefourth region having a greater modulus of elasticity than the thirdregion; and c) a second aperture extending through the lateral sideportion proximate the forefoot opening within the third region. Thefirst region and the second region are integrally coupled sharing acommon warp. For example when two regions are formed during a commonweaving operation, they share a common warp. This is in contrast to twopreviously cut portions that are then coupled (e.g., sewn or adhered),which do not share a common weaving warp thread. The third region andthe fourth region are integrally coupled sharing a common warp. In anexemplary aspect, it is contemplated that the first, second, third, andfourth regions are formed as part of a substantially planar shoe upperduring a single weaving operation.

Exemplary Aspects—Integrally Woven Lockout Strands

The following exemplary aspects make reference to features previouslydiscussed with respect to FIGS. 9-11 hereinabove. While specificfeatures are identified from FIGS. 9-11, they are not limiting butinstead provided for convenience. Stated differently, it is intended forthe additional aspects that are enabled herein, but that are notspecifically identified below, are also contemplated within the scope ofthe present invention. Therefore, the exemplary part numbering providedhereinafter is not intended to limit the scope of the present invention.

In an exemplary aspect, it is contemplated that a shoe is constructedwith a woven upper (or at least a portion of an upper that is woven).The formation of the woven upper may incorporate wefts having a firstamount of stretch (i.e., a modulus of elasticity). Similarly the warpsmay also have a degree of stretch, such as a second modulus ofelasticity. The warps and wefts in this example are contemplated hashaving an amount of stretch that is conducive to forming a function shoeupper that is comfortable to don and wear. However, to achieve desiredperformance results, a lower modulus of elasticity may be utilized instrategic region, such as a non-stretch region extending from a forefootopening to a sole coupling portion (i.e., a portion of the upper towhich a sole portion is coupled). The non-stretch region may be achievedby interweaving lockout strands with the warps and/or wefts of theupper. In this example, the non-stretch region is achieved byincorporating a lockout strand having a modulus of elasticity hat isless than the proximate warp(s) and/or weft(s).

With respect to the orientation of the lockout strands relative to theunderlying warps and/or wefts, it is contemplated that the lockoutstrands may be orthogonally oriented to the warps or wefts, they may benon-orthogonally oriented to the warps/wefts, and/or they may changefrom a first orientation to a second orientation as they traverse thewarps/wefts.

In another exemplary aspect, it is contemplated that a woven shoe uppermay be formed with a lateral side portion and a medial side portion.Each of the side portions form, at least in part, a forefoot openingthrough which a user may insert a foot. The forefoot opening may bedefined, at least in part, by a forefoot edge. As is typical with anathletic-type shoe, it is contemplated that a plurality of lacingmechanisms, such as eyelets, are positioned proximate the forefoot edgeof both the lateral and the medial side portions. However, in thisexample, a lockout strand extends downwardly from the forefoot edge ofthe medial side towards the lower portion of the medial side proximatethe midsole. Similarly, a second lockout strand extends downwardly fromthe forefoot edge of the lateral side towards the lower portion of thelateral side proximate the midsole. In both lockout strands, they areinterwoven with the upper proximate the lacing mechanism to effectivelytransfer a load applied to the lacing mechanism through the uppertowards the midsole. Therefore, the woven upper may be formed to achievea desired aesthetic or functional purpose and the lockout strands mayaccomplish the desired functional trait of transferring the applied loadaround a user's foot.

As previously discussed, the interweaving of the lockout strand mayinclude incorporating the lockout strand between a warp and a weft suchthat the lockout strand is in a common plane as the warp/weftcombination. This is in contrast to sewing a secondary material into awoven article, in that example, the secondary material in not integrallywoven, but instead alternatives from a first side to a second side of awoven article as it is inserted, this side changing may causedeformations in the woven structure as a load is applied along thelength of the secondary material.

Another exemplary aspect contemplates a shoe construction having a soleand an upper. The upper is again comprised of a medial side portion anda lateral side portion. The medial side portion (and an exemplarylateral side portion) is comprised of a first region. The first region,in this example, extends from a forefoot opening toward the sole, suchas a sole coupling region of the medial side portion. The first regionincorporates a lockout strand, which is a material different from theother warps and wefts within that region of the medial side portion. Theinterweaving of the lockout strand provides this first region with amodulus of elasticity in the direction of the lockout strand that isless than a second region of the medial side portion.

The second region, in this example, extends from the forefoot openingalso towards the sole. However, the second region does not have aninterwoven lockout strand. Therefore, the second region has a greatmodulus of elasticity when measured in the direction of the lockoutstrands of the first region than the first region.

It is contemplated that the first region may coincide with an eyelet andthe second region may coincide with a region between two eyelets alongthe forefoot opening. Therefore, the first region is functional totransfer a load applied to the eyelet downwardly through the upper whilethe second region is functional to provide stretch and comfort to auser. The first region and the second region, in this example, areintegrally formed from a common weaving operation and therefore share atleast a common warp and/or weft.

Exemplary Aspects—Multi-Layered Upper with a Lockout Strand Assembly

The following exemplary aspects make reference to features previouslydiscussed with respect to FIGS. 12-13 hereinabove. While specificfeatures are identified from FIGS. 12-19, they are not limiting butinstead provided for convenience. Stated differently, it is intended forthe additional aspects that are enabled herein, but that are notspecifically identified below, are also contemplated within the scope ofthe present invention. Therefore, the exemplary part numbering providedhereinafter is not intended to limit the scope of the present invention.

In an exemplary aspect, a shoe construction is comprised of a sole and awoven upper. The woven upper is comprised of a multi-layer portionhaving a first layer and a second layer. The two layers form a cavity,such as a pocket, a tunnel, or other volume of space between the layers.The upper is also comprised of a reinforcement portion that forms anaperture through the first layer. The reinforcement portion may be anintegrally formed portion or it may be a post-weaving portion. Forexample, it is contemplated hat a heat activated laminate (or anylaminate) may be affixed to the upper to form the reinforcement portion.Additionally, it is contemplated that a mechanical reinforcement, suchas a metallic eyelet may also be added as a reinforcement portion, in anexemplary aspect.

The upper may also be comprised of a lockout strand. The lockout strandextending through the internal cavity of the multi-layer portion of theupper. The lockout strand may then extend out of the cavity through thereinforced aperture of the first layer. For example, it is contemplatedthat a looped portion of the lockout strand may pass through theinternal cavity and extend out of the cavity through an aperture formedproximate a forefoot opening. The looped portion may then serve as alacing mechanism in an exemplary aspect. The remainder of the lockoutstrand may continue down the upper towards the sole as an effectivemechanism for transferring an applied load toward a midsole of the sole,in this example.

In an exemplary aspect, it is contemplated that a plurality of aperturesare formed in the first layer (e.g., the exterior layer or the interiorlayer). The apertures may be formed during the weaving process toprovide a functional zone. As previously discussed, the functional zonesmay be a stretch zone caused by the apertures or a ventilation zonecaused by the apertures.

Another exemplary aspect is directed to a shoe construction comprised ofa woven shoe upper having both a medial side portion and a lateral sideportion. The medial side portion is comprised of an integrally wovenmulti-layer portion forming a medial side internal cavity. Theintegrally woven aspect may be achieved using a jacquard loom that iscapable of forming at least two sheds from a common grouping of warps.Additional loom configurations (e.g., a dobby loom) may also beimplemented to achieve an integrally woven multi-layer article.

In this example, it is contemplated that a number of apertures extendthrough an exterior later of the medial multi-layer portion near theforefoot opening. Additionally, it is contemplated that another of otherapertures extend through an exterior layer of the lateral multi-layerportion. These apertures may serve as an aperture through which alockout strand may exit from an internal volume of the upper to anexterior location of the upper, such as near the forefoot opening.Unlike a typical eyelet that passes through the upper to allow threadingof a lace, the apertures discussed in this example do not pass throughall layers of an upper. Instead, the apertures, in this example, merelyprovide a means of egress and ingress to the cavity in the multi-layerwoven upper.

As with other exemplary multi-layer woven article provided herein, it iscontemplated that both a first layer and a second layer of a multi-layerwoven article diverge from a common woven layer. For example, two ormore layers may share a common weft, such as along a single layerportion. Similarly, it is contemplated that two or more layers may sharea common warp, such as along a common layer portion. Therefore, unlikewhen two independently created articles are coupled in a post-processingfashion (e.g., sewing, bonding), an integrally formed multi-layer wovenarticle is formed from a common weaving operation.

Additional Aspects

FIG. 14 depicts an additional aspect of a substantially planar wovenshoe upper in both a front and a related back perspective, in accordancewith aspects of the present invention. Various functional regions aredepicted, such as stretch, non-stretch, dimensional, breathability, andthe like. Additionally depicted is a region in which a heel counter maybe inserted. In an exemplary aspect, it is contemplated that amulti-layer weaving technique may be implemented to form a pocket orcavity into which a heel counter may be inserted. In an exemplaryaspect, an enclosed cavity is formed during a weaving operation;however, upon cutting the heel portion from a larger woven article(e.g., beam width portion), the enclosed cavity becomes accessible forthe insertion of a supplemental material, such as a structural heelcounter piece. A pocket for receiving the heel counter piece is depictedin FIG. 14 proximate the heel portion 206.

While aspects of FIG. 14 a similar to that of FIG. 2 discussedpreviously, the lateral heel edge 240, when coupled with the medial heeledge 241, is located more toewardly in FIG. 14 than in FIG. 2. Stateddifferently, the exemplary substantially planar woven upper depicted inFIG. 14 has a more forwardly positioned coupling seem than that of FIG.2. An additional difference between FIG. 2 and FIG. 14 uppers is thelocation and position of the medial flap. In FIG. 14, a portion of themedial flap is formed heelwardly from the lateral heel edge 240. As aresult, a first portion of the medial flap is located toewardly of themedial heel edge 241 and a second portion of the medial flap is locatedheelwardly of the lateral heel edge 240. Further, FIG. 14 contemplated amulti-layer weave that creates a first layer forming a back surface a da second layer forming the front surface. The multi-layer aspects may beutilized to provide a varied functional zones by the varied layers. Forexample, the back layer (i.e., closest to the skin) may be woven to forma comfort layer, such as a terry cloth-type weave. Similarly, theexterior layer may be formed to provide a functional characteristic,such as breathability through a leno weave type technique. As previouslydiscussed, it is contemplated that a variety of weaving techniques maybe implemented at various location of the article and at differentlayers. Stated differently, it is contemplated that a first layer at afirst location may be formed with a first weaving technique and a secondlayer at the first location is formed with a second weaving technique,in an exemplary aspect.

While the number of FIG. 14 is provided, it is provided to identifycomparable portions to that which was discussed in FIG. 2 hereinabove.Therefore, it is contemplated that additional features and alternativefeatures are found in FIG. 14 than explicitly described with respect toFIG. 2.

FIG. 15 depicts a spectrum of weaving techniques to achieve a variedmodulus of elasticity, in accordance with aspects of the presentinvention. The spectrum of stretch is laid out along a continuum 1502that extend between a stretch end 1504 and a non-stretch end 1506. Afunctional zone may utilize one or more weaving techniques associatedwith a varied degree of elasticity based on the continuum 1502. Forexample, near the end 1504 when a stretch functional zone is desired, asatin weave technique may be implemented. Exemplary satin weavetechniques are illustrated in region 1508 of the continuum 1502.Similarly, when desiring a medium level of elasticity, weavingtechniques (e.g., interlock, hatching, slit, and leno) may beimplemented, as illustrated in a region 1510. Further, at a lower degreeof modulus of elasticity a plain weave may be implemented, asillustrated in a region 1512. Finally, nearest the end 150 demonstratinga non-stretch region of the continuum 1502, a twill weave may beimplemented, as depicted at region 1514. Therefore, a resultant amountof stretch may be determined based on the continuum 1502, in anexemplary aspect.

FIG. 16 depicts and exemplary heel region 1600 having a dimensional zoneand a heel counter zone within a woven upper portion, in accordance withexemplary aspects of the present invention. In particular, the heelregion 1600 is cut in half forming an un-finished portion 1602 and afinished portion 1604 that are separated by a cutline 1606, Theun-finished portion 1602 include a portion 1603 that is to be removed toform the shoe upper. The portion 1603 has been removed and a finishededge is formed on the finished portion 1604, as will be discussed ingreater detail hereinafter at FIG. 17.

The dimensional zone is constructed having a pocket 1610 in to whichdimensional material is inserted. The dimensional material may be a foammaterial 1608 that is injected. Similarly depicted is a heel counterpocket 1614 into which a heel counter material 1612, such as apolymer-based material, is inserted. As previously discussed and will bediscussed in more detail with respect to FIG. 18, multiple weavingtechniques may be implemented for the various zones, in an exemplaryaspect.

FIG. 17 depicts a cut profile of an ankle collar region 1700, inaccordance with aspects of the present invention. The ankle collar maybe formed from a multi-layer woven structure into which a dimensionalmaterial 1705 is inserted. The multi-layer material may be formed from afirst layer 1702 and a second layer 1704. The apex (e.g., top portion)of the ankle collar may be defined at a position 1710. In an exemplaryaspect, an upper is formed from a larger portion of material such that aportion of the larger material is removed by cutting, melting, or othertechniques. As a result of the removal of excess material, an edge maybe formed. In an effort to provide a well fitting and good feelingarticle of footwear, the edge that is formed may not be desired to beproximate a skin-contacting region of the shoe. Therefore, in anexemplary aspect, the edge is positioned away from a user's potentialcontact regions. However, in a multi-layer woven article, when thearticle is cut, the edge will typically be formed at the apex 1710,which may be in a skin-contacting region. Therefore, it is contemplatedthat a variation in modulus of elasticity between an outer layer 1704and an interior layer 1708 may be utilized to shift the edge from theapex 1710 to a position 1706 that is more towards an exterior of theankle collar than the apex 1710. This shift in location may beaccomplished by utilizing a weaving technique (or material selection) atthe interior layer 1708 that has a greater modulus of elasticity thanthe outer layer 1704. Consequently, when tension is applied across theinterior layer 1708 and the outer layer 1704, the interior layer 1708stretches a greater degree than the outer layer 1704. Therefore, theedge formed when the ankle collar is cut from the greater portion ofmaterial is positioned at 1706 rather than the apex 1710. The insertionof a dimensional material may further exaggerate the movement of theedge away from the apex 1710 as a greater load is applied across theouter layer 1704 and the interior layer 1708.

In an exemplary aspect, it is contemplated that a portion of a wovenarticle is treated with a material in a location prior to cutting at thelocation to provide a finished edge or an edge that is more easilyfinished. For example, it is contemplated that a silicone or a urethane(or any material that may bond) is applied to the woven article along aportion that is intended to be an edge (e.g., where a cut may be made).After curing, the applied material may be effective for substantiallymaintaining the wefts and warps in a desired relative location to oneanother. Stated differently, it is contemplated that prior to cutting aportion of a woven article from the woven article, that a material isapplied proximate the cut location. The applied material helps to keepthe edge from fraying (unraveling). However, as discussed above, thisapplied material may form an edge that is not desirable to be in contactwith a wearer's skin. Therefore, as discussed above, manipulating thelocation at which the edge ultimately is positioned (e.g., outwardlyfrom the apex location) using a variable modulus of elasticity weavebetween the top layer and the bottom layer may be desired, in anexemplary aspect.

FIG. 18 depicts a multi-region woven portion 1800, in accordance withaspects of the present invention. In a common weaving operationperformed by a jacquard-enabled loom, four unique regions are formed.For example, a first region 1802, a second region 1804, a third region1806, and a fourth region 1808 are formed. In an exemplary aspect, thewoven portion 1800 may be a toe box region of a substantially planarwoven shoe upper. The first region 1802 may be formed as a reinforcementfunctional zone that is resistant to abrasion, such as the leading edgeof a toe region. It is contemplated that the first region 1802 may beformed with a twill weaving technique that implements a durablefilament/fiber. Consequently, it is contemplated that the first region1802 has a relatively low modulus of elasticity.

The second region 1802 may also be formed with a twill weavingtechnique. However, it is contemplated that a variation in the weavingmay be formed between the first region 1802 and the second region 1804.For example, an alternative twill weaving technique may be utilizedand/or alternative materials may be utilized between the regions toaccomplish varied functional characteristics. The third region 1806 mayutilize a satin weaving technique to provide a greater degree ofelasticity than found in the first region 1802 or the second region1804. The third region 1806 is effective to absorb tension forcesexerted across the woven article to allow a breathability region (e.g.,region 1808) to continue to provide an effective transfer of air andmoisture through the woven article. The fourth region 1808 may be formedutilizing an open-plain weaving technique that is effective to form abreathability region within the woven article.

As depicted in FIG. 18, a variety of weaving techniques in a variety ofregion formations may be implemented in exemplary aspects of the presentinvention. As such, FIG. 18 depicts a variety of weaving techniquesformed in a common/integrated weaving process that are effective toachieve functional zones/regions within a woven article of footwear.

FIG. 19 depicts an exemplary woven article 1900 that utilizes a jacquardmechanism in combination with a leno weaving technique, in accordancewith aspects of the present invention. As a result, functionalcharacteristics may be formed in a region, such as reinforcement and/ordimensional portions 1902 based on a jacquard mechanism while alsoimplementing breathability regions 1904 based on a leno weavingtechnique during a common weaving operation.

FIG. 20 depicts an exemplary woven article 2000 having leno twistedwefts 2004 running in the vertical direction and pulled (spaced in awave-like formation) warps 2002 running in the horizontal direction, inaccordance with aspects of the present invention. The combination of aleno twisting technique on the wefts 2004 in combination with thephysical manipulation of the warps 2002 result in the creation ofopenings 2006. The opening 2006 may provide a breathability functionalzone within a woven shoe portion.

FIG. 21 depicts an exemplary woven article 2100 having a monofilamentwarp running in the horizontal direction and wefts running in thevertical direction, in accordance with aspects of the present invention.The wefts may float in formation over the warps forming the openings2102. It is contemplated that the openings 2102 may be formed in anlocation at any size and at any relative position to one another.Further, it is contemplated that the monofilament may be removed ordisplaced from the openings (e.g., melted). For example, a laser orother heat generating device may selectively terminate the monofilament(or any filament) within the openings to provide a clear opening throughwhich heat, moisture, light, and the like may pass.

While embodiments provided herein refer to a substantially planar upper,it is understood that features described herein may be incorporated intoarticles formed in a non-substantially planar manner. For example,aspects directed to and including lockout strands may be implemented inany type of footwear or article, regardless substantial planarness.

Although the shoe construction is described above by referring toparticular aspects, it should be understood that the modifications andvariations could be made to the shoe construction described withoutdeparting from the intended scope of protection provided by thefollowing claims.

1. A woven planar shoe upper comprising: a woven first side portionextending from a heel end towards a toe end and also extending from anupper edge towards a first side edge, the upper edge defining, in part,a forefoot opening and an ankle opening into an interior of the shoeupper portion when the shoe upper portion is formed as a non-planar shoeupper; a woven second side portion extending from the heel end towardsthe toe end and also extending from the upper edge towards a second sideedge, the second side portion and the woven first side portion form, inpart, a medial side and a lateral side of the shoe upper portion whenthe shoe upper portion is formed as a non-planar shoe upper; a firstside sole flap coupled at least partially to the woven first sideportion, and a second side sole flap coupled at least partially to thewoven second side portion; an integrally formed stretch portion definedby a convergence of the woven first side portion and the first side soleflap; and an integrally formed perimeter region at least partiallysurrounding the woven planar shoe upper, the perimeter region having atleast a first layer and a second layer.
 2. The shoe upper of claim 1,wherein the integrally formed perimeter region has a lower modulus ofelasticity than the woven first side portion.
 3. The shoe upper of claim1, wherein the integrally formed perimeter region has a higher modulusof elasticity than the woven first side portion.
 4. The shoe upper ofclaim 1, wherein the first layer of the perimeter region is formed froma different weaving technique than the second layer of the perimeterregion.
 5. The shoe upper of claim 1, wherein the integrally formedperimeter portion forms at least a portion of the ankle opening of thewoven planar shoe upper.
 6. The shoe upper of claim 1, wherein theintegrally formed perimeter portion forms at least a portion of thefirst side sole flap.
 7. The shoe upper of claim 6, wherein theintegrally formed perimeter portion forms at least a portion of thewoven first side portion.
 8. The shoe upper of claim 1, wherein theintegrally formed perimeter portion forms at least a portion of thesecond side sole flap.
 9. The shoe upper of claim 8, wherein theintegrally formed perimeter portion forms at least a portion of thewoven second side portion.
 10. The shoe upper of claim 1, wherein theintegrally formed perimeter portion forms at least a portion of the toeend.
 11. The shoe upper of claim 1, wherein the woven first side portionand the woven second side portion include a filler yarns that forms athickness at the woven first side portion and the woven second sideportion that is greater than another portion of the shoe upper.
 12. Awoven shoe upper comprising: a woven first side portion extending from aheel end towards a toe end and also extending from an upper edge towardsa first side edge; a woven second side portion extending from the heelend towards the toe end and also extending from the upper edge towards asecond side edge; a first side sole flap extending at least partiallyfrom the woven first side portion, and a second side sole flap extendingat least partially from the woven second side portion; an integrallyformed stretch portion defined by a convergence of the woven first sideportion and the first side sole flap; and an integrally formed perimeterregion at least partially circumscribing the woven planar shoe upper,the perimeter region having at least a first layer and a second layer.13. The woven shoe upper of claim 12, wherein the perimeter region has alower modulus of elasticity than the woven first side portion.
 14. Thewoven shoe upper of claim 12, wherein the perimeter region has a highermodulus of elasticity than the woven first side portion.
 15. The shoeupper of claim 12, wherein the first layer of the perimeter region is afirst woven structure and the second layer of the perimeter region is asecond woven structure different from the first woven structure.
 16. Theshoe upper of claim 12, wherein the integrally formed perimeter at leastpartially circumscribes the heel end of the woven planar shoe upper. 17.The shoe upper of claim 12, wherein the integrally formed perimeter atleast partially circumscribes the toe end of the woven planar shoeupper.
 18. The shoe upper of claim 12, wherein the integrally formedperimeter at least partially circumscribes the toe end of the wovenplanar shoe upper.
 19. A shoe construction comprising: a sole; and anupper, the upper comprising: a woven first side portion extending from aheel end towards a toe end and also extending from an upper edge towardsa first side edge, the upper edge defining, in part, a forefoot openingand an ankle opening into an interior of the shoe upper portion when theshoe upper portion is formed as a non-planar shoe upper; a woven secondside portion extending from the heel end towards the toe end and alsoextending from the upper edge towards a second side edge, the secondside portion and the woven first side portion form, in part, a medialside and a lateral side of the shoe upper portion when the shoe upperportion is formed as a non-planar shoe upper; and an integrally formedperimeter region at least partially surrounding the woven planar shoeupper, the perimeter region having at least a first layer and a secondlayer.
 20. The woven shoe upper of claim 19, wherein the perimeterregion has a lower modulus of elasticity than the woven first sideportion.